US20180347879A1 - Air conditioner provided with means for predicting and detecting failure in compressor and method for predicting and detecting the failure - Google Patents
Air conditioner provided with means for predicting and detecting failure in compressor and method for predicting and detecting the failure Download PDFInfo
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- US20180347879A1 US20180347879A1 US15/757,779 US201515757779A US2018347879A1 US 20180347879 A1 US20180347879 A1 US 20180347879A1 US 201515757779 A US201515757779 A US 201515757779A US 2018347879 A1 US2018347879 A1 US 2018347879A1
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B49/00—Arrangement or mounting of control or safety devices
- F25B49/02—Arrangement or mounting of control or safety devices for compression type machines, plants or systems
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B35/00—Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for
- F04B35/04—Piston pumps specially adapted for elastic fluids and characterised by the driving means to their working members, or by combination with, or adaptation to, specific driving engines or motors, not otherwise provided for the means being electric
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
- F04B49/06—Control using electricity
- F04B49/065—Control using electricity and making use of computers
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
- F04B49/10—Other safety measures
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C23/00—Combinations of two or more pumps, each being of rotary-piston or oscillating-piston type, specially adapted for elastic fluids; Pumping installations specially adapted for elastic fluids; Multi-stage pumps specially adapted for elastic fluids
- F04C23/008—Hermetic pumps
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C28/00—Control of, monitoring of, or safety arrangements for, pumps or pumping installations specially adapted for elastic fluids
- F04C28/28—Safety arrangements; Monitoring
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B13/00—Compression machines, plants or systems, with reversible cycle
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B49/00—Arrangement or mounting of control or safety devices
- F25B49/005—Arrangement or mounting of control or safety devices of safety devices
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B2203/00—Motor parameters
- F04B2203/02—Motor parameters of rotating electric motors
- F04B2203/0201—Current
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B2203/00—Motor parameters
- F04B2203/02—Motor parameters of rotating electric motors
- F04B2203/0212—Amplitude of the electric current
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B2203/00—Motor parameters
- F04B2203/02—Motor parameters of rotating electric motors
- F04B2203/0213—Pulses per unit of time (pulse motor)
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B2207/00—External parameters
- F04B2207/70—Warnings
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C18/00—Rotary-piston pumps specially adapted for elastic fluids
- F04C18/02—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents
- F04C18/0207—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents both members having co-operating elements in spiral form
- F04C18/0215—Rotary-piston pumps specially adapted for elastic fluids of arcuate-engagement type, i.e. with circular translatory movement of co-operating members, each member having the same number of teeth or tooth-equivalents both members having co-operating elements in spiral form where only one member is moving
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C2270/00—Control; Monitoring or safety arrangements
- F04C2270/05—Speed
- F04C2270/052—Speed angular
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C2270/00—Control; Monitoring or safety arrangements
- F04C2270/07—Electric current
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C2270/00—Control; Monitoring or safety arrangements
- F04C2270/60—Prime mover parameters
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04C—ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; ROTARY-PISTON, OR OSCILLATING-PISTON, POSITIVE-DISPLACEMENT PUMPS
- F04C2270/00—Control; Monitoring or safety arrangements
- F04C2270/80—Diagnostics
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2313/00—Compression machines, plants or systems with reversible cycle not otherwise provided for
- F25B2313/005—Outdoor unit expansion valves
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2313/00—Compression machines, plants or systems with reversible cycle not otherwise provided for
- F25B2313/027—Compression machines, plants or systems with reversible cycle not otherwise provided for characterised by the reversing means
- F25B2313/02741—Compression machines, plants or systems with reversible cycle not otherwise provided for characterised by the reversing means using one four-way valve
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
- F25B—REFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
- F25B2700/00—Sensing or detecting of parameters; Sensors therefor
- F25B2700/15—Power, e.g. by voltage or current
- F25B2700/151—Power, e.g. by voltage or current of the compressor motor
Definitions
- the present invention relates to a means for predicting and detecting a failure in a compressor provided in a refrigerating device or an air conditioner and a method for predicting and detecting the failure.
- Patent Literature 1 A background art of the present invention is described in Patent Literature 1.
- an instantaneous current or instantaneous voltage applied to a compressor is detected. Any failure in the compressor is predicted and diagnosed by estimating an internal state of the compressor, especially, a motor driving torque from this detection value and further estimating poor lubrication, liquid compression, and the like.
- a refrigerating device for example, an air conditioner in which a refrigerating cycle is composed of a compressor, a condenser, an expansion mechanism, and a vaporizer, inoperativeness resulting from any failure in the compressor will significantly impair a user's comfort.
- One of means for achieving stable operation of an air conditioner or a refrigerating device is to detect any failure in a compressor at an early stage to avoid sudden inoperativeness for users.
- any anomaly is detected at a compressor internal state estimating device by detecting an instantaneous current or instantaneous voltage applied to a compressor and estimating a motor driving torque using an arithmetic expression.
- this configuration described in Patent Literature 1 requires the compressor internal state estimating device and thus preparing a control board for the compressor internal state estimating device. Therefore, an outdoor unit of an air conditioner with a limited space in the machine poses a difficult problem in terms of price as well as structure.
- the present invention provides an air conditioner equipped with a means for predicting and detecting any failure in a compressor and a method for predicting and detecting the failure, making it possible to address the above-mentioned problem associated with the related art and detect any anomaly at an early stage.
- the present invention provides an air conditioner equipped with a heat exchanger, a compressor, piping connecting the heat exchanger and the compressor, and a control unit controlling the compressor and having a means for predicting and detecting any failure in the compressor.
- the means for predicting and detecting any failure in the compressor is composed of: a current detecting part detecting a driving current for driving the compressor; a pulsation detecting part detecting pulsation in the driving current detected by the current detecting part; and an anomaly determining part predicting or detecting any failure in the compressor based on a magnitude and a duration of the pulsation in the driving current detected by the pulsation detecting part.
- the present invention provides a method for predicting and detecting any failure in a compressor of an air conditioner equipped with a heat exchanger, the compressor, piping connecting the heat exchanger and the compressor, and a control unit controlling the compressor.
- the method includes the steps of: detecting a driving current for driving the compressor by a current detecting part; detecting pulsation in the driving current detected by the current detecting part by a pulsation detecting part; and predicting or detecting any failure in the compressor by an anomaly determining part based on a magnitude and a duration of the pulsation in the driving current detected by the pulsation detecting part.
- an air conditioner equipped with a means for predicting and detecting any failure in a compressor and a method for predicting and detecting the failure in accordance with the present invention it is possible to detect any early-stage anomaly in the compressor, which is conventionally difficult to detect through an absolute value of current or voltage, to maintain the air conditioner and replace parts of the air conditioner as planned, and to enhance an air conditioner user's comfort and reliability from the user.
- FIG. 1 is a block diagram illustrating a refrigerating cycle configuration of an air conditioner in an example of the present invention.
- FIG. 2 is a sectional view illustrating an internal structure of a compressor used in an air conditioner in an example of the present invention.
- FIG. 3 is a block diagram schematically illustrating a compressor and a control unit used in an air conditioner in an example of the present invention.
- FIG. 4A is a block diagram illustrating a configuration of a current detecting part of a control unit used in an air conditioner in an example of the present invention.
- FIG. 4B is a block diagram illustrating a configuration of a phase detecting part of a control unit used in an air conditioner in an example of the present invention.
- FIG. 4C is a block diagram illustrating a pulsation detecting part of a control unit used in an air conditioner in an example of the present invention.
- FIG. 4D is a block diagram illustrating a configuration of an anomaly determining part of a control unit used in an air conditioner in an example of the present invention.
- FIG. 5 is a current waveform chart showing pulsation in a current detected by a current detecting part of a control unit used in an air conditioner in an example of the present invention.
- FIG. 6 is a current pulsation value waveform chart showing pulsation in a current detected by a pulsation detecting part of a control unit used in an air conditioner in an example of the present invention.
- FIG. 7 is a graph showing variation in torque in one turn of a turning scroll observed when a scroll compressor is used in an air conditioner in an example of the present invention.
- FIG. 8 is a graph showing variation in torque in one rotation of a motor observed when a rotary compressor is used in an air conditioner in an example of the present invention.
- FIG. 9 is a flowchart illustrating a flow of anomaly determination processing at an anomaly determining part of a control unit used in an air conditioner in an example of the present invention.
- FIG. 10 is a flowchart illustrating a flow of anomaly determination processing at a control unit used in an air conditioner in an example of the present invention.
- the present invention relates to an air conditioner provided with a function of predicting and detecting any failure in a compressor.
- FIG. 1 illustrates a refrigerating cycle of a typical air conditioner 1 .
- the air conditioner 1 includes an outdoor unit 10 and an indoor unit 30 and these units are in communication with each other through gas connection piping 2 and liquid connection piping 3 .
- the outdoor unit 10 includes a compressor 11 , a four-way valve 12 , an outdoor heat exchanger 13 , an outdoor blower 14 , an outdoor expansion valve 15 , an accumulator 20 , a compressor suction pipe 16 , a gas refrigerant pipe 17 , and a control unit 4 .
- the compressor 11 and the accumulator 20 are connected with each other through the compressor suction pipe 16 and the four-way valve 12 and the accumulator 20 are connected with each other through the refrigerant pipe 17 .
- the compressor 11 compresses and discharges a refrigerant into piping.
- a flow of a refrigerant is changed and an operation is switched between cooling and heating by changing the setting of the four-way valve 12 .
- the outdoor heat exchanger 13 exchanges heat between a refrigerant and outside air.
- the outdoor blower 14 supplies outside air to the outdoor heat exchanger 13 .
- the outdoor expansion valve 15 reduces the pressure of a refrigerant to lower the temperature of the refrigerant.
- the accumulator 20 is provided for retaining returned liquid during a period of transition and adjusts a refrigerant to an appropriate level of dryness.
- the indoor unit 30 includes an indoor heat exchanger 31 , an indoor blower 32 , and an indoor expansion valve 33 .
- the indoor heat exchanger 31 exchanges heat between a refrigerant and inside air.
- the indoor blower 32 supplies outside air to the indoor heat exchanger 31 .
- the indoor expansion valve 33 can change a flow rate of a refrigerant flowing through the indoor heat exchanger 31 by varying an amount of throttling of the indoor expansion valve.
- Solid-line arrows in FIG. 1 show a flow of a refrigerant during a cooling operation of the air conditioner 1 .
- the four-way valve 12 brings the discharge side of the compressor 11 and the outdoor heat exchanger 13 into communication with each other and brings the accumulator 20 and the gas connection piping 2 into communication with each other as shown by the solid lines.
- a high-temperature, high-pressure gas refrigerant compressed and discharged from the compressor 11 flows into the outdoor heat exchanger 13 by way of the four-way valve 12 and cooled and condensed by outside air sent by the outdoor blower 14 .
- the condensed liquid refrigerant is sent to the indoor unit 30 by way of the outdoor expansion valve 15 and the liquid connection piping 3 .
- the liquid refrigerant that flowed into the indoor unit 30 is reduced in pressure by the indoor expansion valve 33 and turned into a low-pressure, low-temperature gas-liquid two-phase refrigerant, which in turn flows into the indoor heat exchanger 31 .
- the gas-liquid two-phase liquid refrigerant is heated and vaporized by indoor air sent by the indoor blower 32 and is turned into a gas refrigerant. At this time, inside air is cooled by the latent heat of vaporization of the refrigerant and cold air is sent into the room. Thereafter, the gas refrigerant is returned to the outdoor unit 10 by way of the gas connection piping 2 .
- the gas refrigerant that returned to the outdoor unit 10 flows into the accumulator 20 by way of the four-way valve 12 and the gas refrigerant pipe 17 .
- the refrigerant is adjusted to a predetermined level of dryness at the accumulator 20 and sucked into the compressor 11 by way of the compressor suction pipe 16 , and compressed at the compressor 11 again. This completes a single refrigerating cycle.
- FIG. 1 shows a flow of a refrigerant during a heating operation of the air conditioner 100 .
- the four-way valve 12 brings the discharge side of the compressor 11 and the gas connection piping 2 into communication with each other and brings the accumulator 20 and the outdoor heat exchanger 13 into communication with each other as shown by the broken lines.
- a high-temperature, high-pressure gas refrigerant compressed and discharged from the compressor 11 is sent to the indoor unit 30 by way of the gas connection piping 2 and the four-way valve 12 .
- the gas refrigerant that flowed into the indoor unit 30 flows into the indoor heat exchanger 31 .
- the refrigerant is cooled and condensed by inside air sent by the indoor blower 32 and turned into a high-pressure liquid refrigerant. At this time, inside air is heated by the refrigerant and warm air is sent into the room. Thereafter, the liquefied refrigerant is returned to the outdoor unit 10 by way of the indoor expansion valve 33 and the liquid connection piping 3 .
- the liquid refrigerant that returned to the outdoor unit 10 is reduced in pressure by a predetermined amount at the outdoor expansion valve 15 and turned into a low-temperature gas-liquid two-phase state and flows into the outdoor heat exchanger 13 .
- the refrigerant that flowed into the outdoor heat exchanger 13 has heat exchanged between the refrigerant and outside air sent by the outdoor blower 14 and is turned into a low-pressure gas refrigerant.
- the gas refrigerant flowing out from the outdoor heat exchanger 13 flows into the accumulator 20 by way of the four-way valve 12 and the gas refrigerant pipe 17 .
- the refrigerant is adjusted to a predetermined level of dryness at the accumulator 20 and is sucked into the compressor 11 and compressed at the compressor 11 again. This completes a single refrigerating cycle.
- FIG. 2 illustrates an internal structure of a high-pressure chamber type scroll compressor as a representative example of a compressor 11 used in the above-mentioned refrigerating cycle of the air conditioner.
- the scroll compressor 11 includes a pressure vessel 103 having a suction pipe 101 and a discharge pipe 102 .
- a discharge pressure chamber 103 a is formed inside the pressure vessel 103 .
- the pressure vessel 103 accommodates a motor 104 having a stator 1041 and a rotor 1042 and a compression mechanical section 105 and refrigerator oil 116 is stored at the lower part of the pressure vessel.
- the pressure vessel 103 is supported on a pedestal 115 .
- the compression mechanical section 105 includes a fixed scroll 106 having a spiral gas passage and a turning scroll 108 having a spiral lap 107 .
- the turning scroll 108 is disposed such that the turning scroll is movable relative to the fixed scroll 106 and a compression chamber 109 is formed by the fixed scroll 106 and the turning scroll 108 being engaged with each other.
- the turning scroll 108 is coupled with an Oldham ring (not shown) that arrests rotation of the turning scroll and yet allows revolution thereof and is coupled with an eccentric portion 111 of a crankshaft 110 rotationally driven by the motor 104 .
- a discharge port 106 a is formed in the fixed scroll 106 .
- the crankshaft 110 By driving of the motor 104 , the crankshaft 110 is rotated and the turning scroll 108 is turned and further a refrigerant sucked from the suction pipe 101 is guided into the compression chamber 109 and gradually compressed there.
- the compressed refrigerant is discharged from the discharge port 106 a of the fixed scroll 106 into the discharge pressure chamber 103 a.
- the crankshaft 110 is supported by a bearing 112 and a bearing 113 .
- the bearing 113 is supported in the pressure vessel 103 by a supporting member 114 .
- a compression mechanism of a refrigerant compressor that is, a compression chamber composed of a fixed scroll and a turning scroll in a scroll compressor is low in dimensional tolerance. If the bearings 112 and 113 are damaged by insufficient lubricating oil or the like, the crankshaft 110 would be made eccentric and the turning scroll 107 and the fixed scroll 106 be brought into contact with each other beyond a normal design value. As a result, galling or the like would occur and prevent a smooth compression stroke and at worst, seizure take place and compression become infeasible. Therefore, when the bearings 112 and 113 are damaged, a swinging load has been produced by eccentricity of the crankshaft.
- this swinging load that is, torque change causes pulsation in a current of the motor. Any anomaly inside the compressor can be detected at an early stage by measuring this current pulsation.
- a refrigerating cycle is constituted by connecting the outdoor unit 10 and the indoor unit 30 through the refrigerant pipe 2 and the liquid connection piping 3 for conditioning air.
- the outdoor unit 10 of the air conditioner 1 includes: the compressor 11 compressing a refrigerant to a high temperature and a high pressure; the compressor motor 104 rotationally driving the compressor 11 ; and the control unit 4 (controlling means) that controls the entire outdoor unit 10 and the entire indoor unit 30 and controls driving of the compressor motor 104 to a desired rotational speed and further detects any anomaly in the compressor motor 104 .
- the control unit 4 includes as means for predicting and detecting any failure (anomaly) in the compressor motor 104 : a current detecting part 5 (current detecting means) detecting an output current of the compressor motor 104 ; a phase detecting part 6 (phase detecting means) detecting a magnetic pole position of the compressor motor 104 ; a motor rotational speed detecting part 7 (rotational speed detecting means) detecting a rotational speed of the compressor motor 104 ; a pulsation detecting part 8 (pulsation detecting means) detecting pulsation in the detected current value of the compressor motor 104 based on the current value and magnetic pole position information; an anomaly determining part 9 determining any compressor anomaly based on the detected pulsation in current value and motor rotational speed; and an anomaly information output portion 91 outputting information on an anomaly determined by the anomaly determining part 9 .
- the control unit 4 also includes: a circuit (not shown) controlling the entire outdoor unit 10 and the entire indoor unit
- the current detecting part 5 includes: a current calculation portion 51 determining a motor current flowing through the compressor motor 104 ; an ⁇ conversion portion 52 ⁇ -converting the determined motor current; a dq conversion portion 53 dq-converting the ⁇ -converted data; and a filtering portion 54 filtering the dq-converted result to calculate a q-axis current feedback value.
- a q-axis current feedback value calculated at the filtering portion 54 is outputted to the pulsation detecting part 8 .
- the phase detecting part 6 includes: a d-axis phase extraction portion 61 that is fed with information dq-converted at the dq conversion portion 53 of the current detecting part 5 and extracts ⁇ dc as d-axis phase information; and a mechanical angle phase calculation portion that calculates a mechanical angle phase ⁇ r using the ⁇ dc information extracted at the d-axis phase extraction portion 61 .
- the calculated mechanical angle phase information is outputted to the pulsation detecting part 8 .
- the pulsation detecting part 8 detects pulsation in a current value of the compressor motor 104 (hereafter, referred to as motor current value) from detection results from the current detecting part 5 and the phase detecting part 6 .
- FIG. 4C illustrates an exemplary configuration of the pulsation detecting part 8 .
- the current detecting part 5 detects a three-phase output current (Iu, Iv, Iw) from the compressor motor 104 at the current calculation portion 51 with the configuration illustrated in FIG. 4A . Specifically, a current flowing through a direct-current portion of an inverter (not shown) driving the compressor motor 104 is measured from a voltage produced across a shunt resistor (not shown). Then, a motor current (Iu, Iv, Iw) is derived by the current calculation portion 51 .
- the detected motor current (Iu, Iv, Iw) is ⁇ -converted and dq-converted in this order at the ⁇ conversion portion 52 and the dq conversion portion 53 in accordance with (Expression 1) below and an obtained result is filtered with a first-order lag at the filtering portion 54 .
- a q-axis current feedback value to be an input value to the pulsation detecting part 8 is calculated.
- ⁇ dc used in dq conversion at the dq conversion portion 53 is in a d-axis phase and indicates a magnetic pole position of the compressor motor 104 .
- a mechanical angle phase ⁇ r as a second input value to the pulsation detecting part 8 is calculated from ⁇ dc. This calculation is represented by (Expression 2) below:
- ⁇ r is calculated by integrating ⁇ r.
- a pulsation component is extracted from the above-mentioned two inputs, the q-axis current feedback value and the mechanical angle phase ⁇ r.
- sin ⁇ r and cos ⁇ r are calculated from the mechanical angle phase ⁇ r inputted from the phase detecting part 5 through sin and cos calculations at a calculation portion 81 .
- Calculation results are respectively multiplied by a q-axis current feedback value inputted from the current detecting part 5 at multipliers 811 and 812 and filtered with a first-order lag at a filtering portion 82 to remove a high frequency component.
- a filtering time constant T for the first-order lag filtering at the filtering portion 82 is set by simulation based on testing on an actual machine such that a torque pulsation period can be extracted. A more specific description will be given. To extract a pulsation component, a time constant T for filtering must be made larger than a pulsation period; therefore, a time constant is set to a value larger than a rotation period of the compressor 11 at which torque pulsation occurs.
- FIG. 4C shows 500 ⁇ s of Ts and 500 ms of Ta as examples of the set values of sampling period Ts and filter time constant Ta.
- FIG. 5 is a waveform chart indicating pulsation in a current detected at the current detecting part 5 when an anomaly occurs in the compressor 11 of the air conditioner 1 and a swinging load is produced.
- Such anomalies that a swinging load is produced in the compressor 11 include damage to the bearing 112 or 113 supporting the rotation mechanism of the compressor 11 , liquid compression in the compression chamber 109 , poor lubrication at a contact area in the compression mechanical section, and the like.
- the curve 50 a represents a current value waveform in a normal state detected at the current detecting part 5 and the curve 50 b represents a current value waveform at the time of a compressor anomaly.
- the current detecting part 5 illustrated in FIG. 3 detects a current of the compressor motor 104 with a certain sampling period.
- FIG. 6 indicates threshold values Ia 1 , Ia 2 used for detecting a compressor anomaly from a current pulsation value.
- the threshold values Ia 1 , Ia 2 are set beforehand the operation, based on the testing of a normal compressor and a compressor inside which an anomaly is observed or the like.
- a current pulsation value Ia exceeds the threshold value Ia 1 for a certain period of time (T 1 ) as indicated by the broken line in the graph, an air conditioner user is notified of an anomaly from the anomaly information output portion 91 .
- maintenance personnel for the air conditioner are notified of the anomaly in the air conditioner by remote monitoring or a smartphone through the Internet or the like.
- the air conditioner can be maintained at an early stage.
- the anomaly When the current pulsation value exceeds the threshold Ia 1 for a certain period of time (T 1 ), the anomaly is at an initial stage; therefore, an operation can be continued during a predetermined period of time only by notifying a compressor anomaly to the user.
- T 1 a certain period of time
- Ia 1 is effective in detecting any event, such as damage to a bearing, in which an anomaly gradually progresses in proportion to an operating time of the compressor.
- FIG. 4D illustrates a configuration of the above-mentioned anomaly determining part 9 determining any anomaly in the compressor 11 .
- the anomaly determining part 9 includes: a storage portion 91 storing threshold values Ia 1 , Ia 2 beforehand the operation; a first comparison portion 92 comparing information on a current pulsation value Ia outputted from the pulsation detecting part 8 with Ia 1 stored in the storage portion; a second comparison portion 93 comparing information on a current pulsation value Ia outputted from the pulsation detecting part 8 with Ia 2 stored in the storage portion 91 ; and the anomaly information output portion 94 that, in response to information on results of comparisons at the first comparison portion 92 and the second comparison portion 93 , outputs anomaly information.
- FIG. 7 is a graph indicating change in torque observed while a turning scroll is rotated by one turn in a scroll compressor.
- a refrigerant compression stroke at a scroll compressor as mentioned above, a refrigerant sucked into a compression chamber is compressed as a volume of the compression chamber is gradually reduced with rotation of the turning scroll.
- torque is changed due to a refrigerant gas load while the turning scroll is rotated by one turn.
- a torque is changed by one cycle while a turning scroll is rotated by one turn, that is, a compressor motor is rotated by one turn. Therefore, even in a normal compressor, pulsation occurs in the number of rotations first-order component of the compressor motor.
- Rotary compressors are also frequently used as a compressor of an air conditioner 1 .
- rotary compressors are also provided with a displacement type compression mechanism, in which the volume of a compression chamber is varied by a rotating rolling piston and as a result, a refrigerant is compressed.
- rotary compressors including one-cylinder type provided with a single compression chamber and two-cylinder type provided with two compression chambers. In case where two compression chambers are provided, compression strokes are shifted by 180 degrees in one rotation of a compressor motor.
- FIG. 8 schematically indicates change in torque that takes place while a compressor motor is rotated by one turn in a rotary compressor.
- the curve 51 a represents torque change in one-cylinder type and the curve 51 b represents torque change in two-cylinder type. Since in two-cylinder type, compression strokes are shifted by 180 degrees, torque change equivalent to two cycles takes place in one rotation of a compressor motor as indicated by the curve 51 b . Therefore, even in a normal compressor, current pulsation is observed in a second-order component of a number of rotations of the compressor motor. Therefore, components of a current pulsation value present in a normal compressor differ depending on the structure of the compressor. For this reason, any anomaly in a compressor of an air conditioner can be detected with higher accuracy by taking the foregoing into account when setting threshold values Ia 1 , Ia 2 for a current pulsation value.
- a current pulsation value Ia outputted from the pulsation detecting part 8 that has received outputs from the current detecting part 5 and the phase detecting part 6 is inputted (S 901 ). Subsequently, it is confirmed whether this current pulsation value Ia has been inputted (S 902 ). When a current pulsation value Ia has not been inputted (NO at S 902 ), the processing is terminated. When a current pulsation value Ia has been inputted (YES at S 902 ), the inputted current pulsation value Ia is compared with a threshold value Ia 1 stored in the storage portion 91 beforehand the operation (S 902 ).
- anomaly information is outputted to the anomaly output part 94 (S 905 ).
- the processing then returns to S 902 and it is confirmed whether a current pulsation value Ia has been inputted from the pulsation detecting part 8 .
- the current pulsation value Ia is compared with the threshold value Ia 2 stored in the storage portion 91 beforehand the operation (S 906 ).
- the processing returns to S 902 and it is confirmed whether a current pulsation value Ia has been inputted from the pulsation detecting part 8 .
- emergency stop information is outputted from the anomaly information output portion 94 for stopping the compressor 11 (S 908 ).
- a motor current is detected at the current calculation portion 51 of the current detecting part 5 (S 1001 ) and ⁇ conversion is performed at the ⁇ conversion portion 52 using a result of the detection (S 1002 ).
- dq conversion is performed at the dq conversion portion 53 (S 1003 ) and a result of the dq conversion is filtered at the filtering portion 54 to calculate a q-axis current feedback value IqFb (S 1004 ).
- the result of dq conversion by the dq conversion portion 53 at S 1003 is also inputted to the phase detecting part 6 .
- ⁇ dc is extracted at the d-axis phase extraction portion 61 and a mechanical angle phase ⁇ r is calculated at the mechanical angle phase calculation portion 62 (S 1005 ).
- the step S 903 in the flowchart described with reference to FIG. 9 is omitted from the flowchart described with reference to FIG. 10 .
- the step S 903 is substantially identical with a loop in which the processing proceeds from S 1007 and is returned to S 1001 by way of S 1009 ; therefore, a description of the step is omitted.
- any failure in a compressor provided in an air conditioner can be predicted and can be detected at an early stage.
- the air conditioner can be used with stability without stopping an operation for reason of any failure in the compressor.
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Abstract
Description
- The present invention relates to a means for predicting and detecting a failure in a compressor provided in a refrigerating device or an air conditioner and a method for predicting and detecting the failure.
- A background art of the present invention is described in
Patent Literature 1. In the technology disclosed inPatent Literature 1, an instantaneous current or instantaneous voltage applied to a compressor is detected. Any failure in the compressor is predicted and diagnosed by estimating an internal state of the compressor, especially, a motor driving torque from this detection value and further estimating poor lubrication, liquid compression, and the like. -
- PTL 1: Japanese Patent Application Laid-Open No. 2008-38912
- In a refrigerating device, for example, an air conditioner in which a refrigerating cycle is composed of a compressor, a condenser, an expansion mechanism, and a vaporizer, inoperativeness resulting from any failure in the compressor will significantly impair a user's comfort.
- In a refrigerating device, such as a refrigerator, for heating or cooling material goods, inoperativeness of the refrigerating device caused by a failure in a compressor leads to damage to material goods to be heated or cooled and causes a not-so-little economic loss. For this reason, in air conditioning for personnel and property, it is important to detect any failure and maintain a compressor before the compressor becomes inoperative for stable operation of the air conditioner or the refrigerating device.
- One of means for achieving stable operation of an air conditioner or a refrigerating device is to detect any failure in a compressor at an early stage to avoid sudden inoperativeness for users.
- In the configuration described in
Patent Literature 1, any anomaly is detected at a compressor internal state estimating device by detecting an instantaneous current or instantaneous voltage applied to a compressor and estimating a motor driving torque using an arithmetic expression. However, this configuration described inPatent Literature 1 requires the compressor internal state estimating device and thus preparing a control board for the compressor internal state estimating device. Therefore, an outdoor unit of an air conditioner with a limited space in the machine poses a difficult problem in terms of price as well as structure. - With respect to instantaneous current and instantaneous voltage, it is difficult to detect a change caused by any anomaly in a compressor before the compressor failure becomes noticeable. For this reason, it is difficult to detect any anomaly in a compressor at an early stage in an air conditioner or a refrigerating device in which a refrigerating cycle is comprised of the compressor, a condenser, an expansion mechanism, and a vaporizer. (Hereafter, these will be collectively referred to as air conditioner.)
- The present invention provides an air conditioner equipped with a means for predicting and detecting any failure in a compressor and a method for predicting and detecting the failure, making it possible to address the above-mentioned problem associated with the related art and detect any anomaly at an early stage.
- To address the above-mentioned problem, the present invention provides an air conditioner equipped with a heat exchanger, a compressor, piping connecting the heat exchanger and the compressor, and a control unit controlling the compressor and having a means for predicting and detecting any failure in the compressor. In the control unit of the air conditioner, the means for predicting and detecting any failure in the compressor is composed of: a current detecting part detecting a driving current for driving the compressor; a pulsation detecting part detecting pulsation in the driving current detected by the current detecting part; and an anomaly determining part predicting or detecting any failure in the compressor based on a magnitude and a duration of the pulsation in the driving current detected by the pulsation detecting part.
- To address the above-mentioned problem, the present invention provides a method for predicting and detecting any failure in a compressor of an air conditioner equipped with a heat exchanger, the compressor, piping connecting the heat exchanger and the compressor, and a control unit controlling the compressor. The method includes the steps of: detecting a driving current for driving the compressor by a current detecting part; detecting pulsation in the driving current detected by the current detecting part by a pulsation detecting part; and predicting or detecting any failure in the compressor by an anomaly determining part based on a magnitude and a duration of the pulsation in the driving current detected by the pulsation detecting part.
- With an air conditioner equipped with a means for predicting and detecting any failure in a compressor and a method for predicting and detecting the failure in accordance with the present invention, it is possible to detect any early-stage anomaly in the compressor, which is conventionally difficult to detect through an absolute value of current or voltage, to maintain the air conditioner and replace parts of the air conditioner as planned, and to enhance an air conditioner user's comfort and reliability from the user.
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FIG. 1 is a block diagram illustrating a refrigerating cycle configuration of an air conditioner in an example of the present invention. -
FIG. 2 is a sectional view illustrating an internal structure of a compressor used in an air conditioner in an example of the present invention. -
FIG. 3 is a block diagram schematically illustrating a compressor and a control unit used in an air conditioner in an example of the present invention. -
FIG. 4A is a block diagram illustrating a configuration of a current detecting part of a control unit used in an air conditioner in an example of the present invention. -
FIG. 4B is a block diagram illustrating a configuration of a phase detecting part of a control unit used in an air conditioner in an example of the present invention. -
FIG. 4C is a block diagram illustrating a pulsation detecting part of a control unit used in an air conditioner in an example of the present invention. -
FIG. 4D is a block diagram illustrating a configuration of an anomaly determining part of a control unit used in an air conditioner in an example of the present invention. -
FIG. 5 is a current waveform chart showing pulsation in a current detected by a current detecting part of a control unit used in an air conditioner in an example of the present invention. -
FIG. 6 is a current pulsation value waveform chart showing pulsation in a current detected by a pulsation detecting part of a control unit used in an air conditioner in an example of the present invention. -
FIG. 7 is a graph showing variation in torque in one turn of a turning scroll observed when a scroll compressor is used in an air conditioner in an example of the present invention. -
FIG. 8 is a graph showing variation in torque in one rotation of a motor observed when a rotary compressor is used in an air conditioner in an example of the present invention. -
FIG. 9 is a flowchart illustrating a flow of anomaly determination processing at an anomaly determining part of a control unit used in an air conditioner in an example of the present invention. -
FIG. 10 is a flowchart illustrating a flow of anomaly determination processing at a control unit used in an air conditioner in an example of the present invention. - The present invention relates to an air conditioner provided with a function of predicting and detecting any failure in a compressor.
- In all the drawings illustrating embodiments of the present invention, members having an identical function will be marked with an identical reference sign and a repetitive description thereof will be omitted in principle. Hereafter, a detailed description will be given to embodiments of the present invention with reference to the drawings.
- However, the present invention should not be construed as being limited to the embodiments described below. Those skilled in art will easily understand that a concrete configuration of the embodiments can be modified without departing from the technical ideas or subject matter of the present invention.
- An example of the present invention in a refrigerating cycle of an air conditioner will be described as a representative example of the present invention. However, the same effect as in the present invention will be brought about in any refrigerating device including a refrigerating cycle composed of a compressor, a condenser, an expansion mechanism, and an evaporator.
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FIG. 1 illustrates a refrigerating cycle of atypical air conditioner 1. Theair conditioner 1 includes anoutdoor unit 10 and anindoor unit 30 and these units are in communication with each other throughgas connection piping 2 andliquid connection piping 3. - The
outdoor unit 10 includes acompressor 11, a four-way valve 12, anoutdoor heat exchanger 13, anoutdoor blower 14, anoutdoor expansion valve 15, anaccumulator 20, acompressor suction pipe 16, agas refrigerant pipe 17, and acontrol unit 4. - The
compressor 11 and theaccumulator 20 are connected with each other through thecompressor suction pipe 16 and the four-way valve 12 and theaccumulator 20 are connected with each other through therefrigerant pipe 17. - The
compressor 11 compresses and discharges a refrigerant into piping. A flow of a refrigerant is changed and an operation is switched between cooling and heating by changing the setting of the four-way valve 12. The outdoor heat exchanger 13 exchanges heat between a refrigerant and outside air. Theoutdoor blower 14 supplies outside air to theoutdoor heat exchanger 13. Theoutdoor expansion valve 15 reduces the pressure of a refrigerant to lower the temperature of the refrigerant. Theaccumulator 20 is provided for retaining returned liquid during a period of transition and adjusts a refrigerant to an appropriate level of dryness. - The
indoor unit 30 includes anindoor heat exchanger 31, anindoor blower 32, and anindoor expansion valve 33. Theindoor heat exchanger 31 exchanges heat between a refrigerant and inside air. Theindoor blower 32 supplies outside air to theindoor heat exchanger 31. Theindoor expansion valve 33 can change a flow rate of a refrigerant flowing through theindoor heat exchanger 31 by varying an amount of throttling of the indoor expansion valve. - A description will be given to a cooling operation of the
air conditioner 1. Solid-line arrows inFIG. 1 show a flow of a refrigerant during a cooling operation of theair conditioner 1. During a cooling operation, the four-way valve 12 brings the discharge side of thecompressor 11 and theoutdoor heat exchanger 13 into communication with each other and brings theaccumulator 20 and the gas connection piping 2 into communication with each other as shown by the solid lines. - A high-temperature, high-pressure gas refrigerant compressed and discharged from the
compressor 11 flows into theoutdoor heat exchanger 13 by way of the four-way valve 12 and cooled and condensed by outside air sent by theoutdoor blower 14. The condensed liquid refrigerant is sent to theindoor unit 30 by way of theoutdoor expansion valve 15 and theliquid connection piping 3. The liquid refrigerant that flowed into theindoor unit 30 is reduced in pressure by theindoor expansion valve 33 and turned into a low-pressure, low-temperature gas-liquid two-phase refrigerant, which in turn flows into theindoor heat exchanger 31. At theindoor heat exchanger 31, the gas-liquid two-phase liquid refrigerant is heated and vaporized by indoor air sent by theindoor blower 32 and is turned into a gas refrigerant. At this time, inside air is cooled by the latent heat of vaporization of the refrigerant and cold air is sent into the room. Thereafter, the gas refrigerant is returned to theoutdoor unit 10 by way of thegas connection piping 2. - The gas refrigerant that returned to the
outdoor unit 10 flows into theaccumulator 20 by way of the four-way valve 12 and thegas refrigerant pipe 17. The refrigerant is adjusted to a predetermined level of dryness at theaccumulator 20 and sucked into thecompressor 11 by way of thecompressor suction pipe 16, and compressed at thecompressor 11 again. This completes a single refrigerating cycle. - A description will be given to a heating operation of the
air conditioner 1. Broken-line arrows inFIG. 1 show a flow of a refrigerant during a heating operation of the air conditioner 100. During a heating operation, the four-way valve 12 brings the discharge side of thecompressor 11 and the gas connection piping 2 into communication with each other and brings theaccumulator 20 and theoutdoor heat exchanger 13 into communication with each other as shown by the broken lines. - A high-temperature, high-pressure gas refrigerant compressed and discharged from the
compressor 11 is sent to theindoor unit 30 by way of the gas connection piping 2 and the four-way valve 12. The gas refrigerant that flowed into theindoor unit 30 flows into theindoor heat exchanger 31. The refrigerant is cooled and condensed by inside air sent by theindoor blower 32 and turned into a high-pressure liquid refrigerant. At this time, inside air is heated by the refrigerant and warm air is sent into the room. Thereafter, the liquefied refrigerant is returned to theoutdoor unit 10 by way of theindoor expansion valve 33 and theliquid connection piping 3. - The liquid refrigerant that returned to the
outdoor unit 10 is reduced in pressure by a predetermined amount at theoutdoor expansion valve 15 and turned into a low-temperature gas-liquid two-phase state and flows into theoutdoor heat exchanger 13. The refrigerant that flowed into theoutdoor heat exchanger 13 has heat exchanged between the refrigerant and outside air sent by theoutdoor blower 14 and is turned into a low-pressure gas refrigerant. The gas refrigerant flowing out from theoutdoor heat exchanger 13 flows into theaccumulator 20 by way of the four-way valve 12 and thegas refrigerant pipe 17. The refrigerant is adjusted to a predetermined level of dryness at theaccumulator 20 and is sucked into thecompressor 11 and compressed at thecompressor 11 again. This completes a single refrigerating cycle. -
FIG. 2 illustrates an internal structure of a high-pressure chamber type scroll compressor as a representative example of acompressor 11 used in the above-mentioned refrigerating cycle of the air conditioner. Thescroll compressor 11 includes apressure vessel 103 having asuction pipe 101 and adischarge pipe 102. Adischarge pressure chamber 103 a is formed inside thepressure vessel 103. Thepressure vessel 103 accommodates amotor 104 having astator 1041 and arotor 1042 and a compressionmechanical section 105 andrefrigerator oil 116 is stored at the lower part of the pressure vessel. Thepressure vessel 103 is supported on apedestal 115. - The compression
mechanical section 105 includes a fixedscroll 106 having a spiral gas passage and aturning scroll 108 having aspiral lap 107. Theturning scroll 108 is disposed such that the turning scroll is movable relative to the fixedscroll 106 and acompression chamber 109 is formed by the fixedscroll 106 and theturning scroll 108 being engaged with each other. Theturning scroll 108 is coupled with an Oldham ring (not shown) that arrests rotation of the turning scroll and yet allows revolution thereof and is coupled with aneccentric portion 111 of acrankshaft 110 rotationally driven by themotor 104. Adischarge port 106 a is formed in the fixedscroll 106. - By driving of the
motor 104, thecrankshaft 110 is rotated and theturning scroll 108 is turned and further a refrigerant sucked from thesuction pipe 101 is guided into thecompression chamber 109 and gradually compressed there. The compressed refrigerant is discharged from thedischarge port 106 a of the fixedscroll 106 into thedischarge pressure chamber 103 a. - The
crankshaft 110 is supported by abearing 112 and abearing 113. Thebearing 113 is supported in thepressure vessel 103 by a supportingmember 114. A compression mechanism of a refrigerant compressor, that is, a compression chamber composed of a fixed scroll and a turning scroll in a scroll compressor is low in dimensional tolerance. If thebearings crankshaft 110 would be made eccentric and theturning scroll 107 and the fixedscroll 106 be brought into contact with each other beyond a normal design value. As a result, galling or the like would occur and prevent a smooth compression stroke and at worst, seizure take place and compression become infeasible. Therefore, when thebearings - At an early stage at which this swinging load is initiated, it is difficult to sense occurrence of an abnormal vibration or an unusual noise. Further, the absolute value of current itself does not vary so much and it is difficult to detect the variation at a control unit. However, this swinging load, that is, torque change causes pulsation in a current of the motor. Any anomaly inside the compressor can be detected at an early stage by measuring this current pulsation.
- Hereafter, a description will be given to a means for predicting and detecting any failure in a compressor and a method for predicting and detecting any failure in a compressor which means and method make it possible to detect any anomaly inside the compressor by measuring the above-mentioned current pulsation.
- As described with reference to
FIG. 1 , in theair conditioner 1, a refrigerating cycle is constituted by connecting theoutdoor unit 10 and theindoor unit 30 through therefrigerant pipe 2 and the liquid connection piping 3 for conditioning air. - As illustrated in
FIG. 2 , theoutdoor unit 10 of theair conditioner 1 includes: thecompressor 11 compressing a refrigerant to a high temperature and a high pressure; thecompressor motor 104 rotationally driving thecompressor 11; and the control unit 4 (controlling means) that controls the entireoutdoor unit 10 and the entireindoor unit 30 and controls driving of thecompressor motor 104 to a desired rotational speed and further detects any anomaly in thecompressor motor 104. - As illustrated in
FIG. 3 , thecontrol unit 4 includes as means for predicting and detecting any failure (anomaly) in the compressor motor 104: a current detecting part 5 (current detecting means) detecting an output current of thecompressor motor 104; a phase detecting part 6 (phase detecting means) detecting a magnetic pole position of thecompressor motor 104; a motor rotational speed detecting part 7 (rotational speed detecting means) detecting a rotational speed of thecompressor motor 104; a pulsation detecting part 8 (pulsation detecting means) detecting pulsation in the detected current value of thecompressor motor 104 based on the current value and magnetic pole position information; ananomaly determining part 9 determining any compressor anomaly based on the detected pulsation in current value and motor rotational speed; and an anomalyinformation output portion 91 outputting information on an anomaly determined by theanomaly determining part 9. Thecontrol unit 4 also includes: a circuit (not shown) controlling the entireoutdoor unit 10 and the entireindoor unit 30; and a circuit (not shown) controlling driving of thecompressor motor 104. - As shown in
FIG. 4A , the current detectingpart 5 includes: acurrent calculation portion 51 determining a motor current flowing through thecompressor motor 104; anαβ conversion portion 52 αβ-converting the determined motor current; adq conversion portion 53 dq-converting the αβ-converted data; and afiltering portion 54 filtering the dq-converted result to calculate a q-axis current feedback value. A q-axis current feedback value calculated at thefiltering portion 54 is outputted to thepulsation detecting part 8. - As illustrated in
FIG. 4B , thephase detecting part 6 includes: a d-axisphase extraction portion 61 that is fed with information dq-converted at thedq conversion portion 53 of the current detectingpart 5 and extracts θdc as d-axis phase information; and a mechanical angle phase calculation portion that calculates a mechanical angle phase θr using the θdc information extracted at the d-axisphase extraction portion 61. The calculated mechanical angle phase information is outputted to thepulsation detecting part 8. - The
pulsation detecting part 8 detects pulsation in a current value of the compressor motor 104 (hereafter, referred to as motor current value) from detection results from the current detectingpart 5 and thephase detecting part 6. -
FIG. 4C illustrates an exemplary configuration of thepulsation detecting part 8. - First, the current detecting
part 5 detects a three-phase output current (Iu, Iv, Iw) from thecompressor motor 104 at thecurrent calculation portion 51 with the configuration illustrated inFIG. 4A . Specifically, a current flowing through a direct-current portion of an inverter (not shown) driving thecompressor motor 104 is measured from a voltage produced across a shunt resistor (not shown). Then, a motor current (Iu, Iv, Iw) is derived by thecurrent calculation portion 51. There are various methods for detecting a motor current (Iu, Iv, Iw) including a method in which a resistor low in resistance value is connected to a motor current output part and a motor current is detected from a voltage applied to the resistor and detection with a current sensor. - The detected motor current (Iu, Iv, Iw) is αβ-converted and dq-converted in this order at the
αβ conversion portion 52 and thedq conversion portion 53 in accordance with (Expression 1) below and an obtained result is filtered with a first-order lag at thefiltering portion 54. Thus, a q-axis current feedback value to be an input value to thepulsation detecting part 8 is calculated. -
- In (Expression 1), θdc used in dq conversion at the
dq conversion portion 53 is in a d-axis phase and indicates a magnetic pole position of thecompressor motor 104. - A mechanical angle phase θr as a second input value to the
pulsation detecting part 8 is calculated from θdc. This calculation is represented by (Expression 2) below: -
Δθr=Δθdc/number of pole pairs (Expression 2) - θr is calculated by integrating Δθr. A pulsation component is extracted from the above-mentioned two inputs, the q-axis current feedback value and the mechanical angle phase θr.
- As illustrated in
FIG. 4A , sin θr and cos θr are calculated from the mechanical angle phase θr inputted from thephase detecting part 5 through sin and cos calculations at acalculation portion 81. Calculation results are respectively multiplied by a q-axis current feedback value inputted from the current detectingpart 5 atmultipliers filtering portion 82 to remove a high frequency component. - A filtering time constant T for the first-order lag filtering at the
filtering portion 82 is set by simulation based on testing on an actual machine such that a torque pulsation period can be extracted. A more specific description will be given. To extract a pulsation component, a time constant T for filtering must be made larger than a pulsation period; therefore, a time constant is set to a value larger than a rotation period of thecompressor 11 at which torque pulsation occurs. - After first-order lag filtering at the
filtering portion 82, results of the filtering are multiplied by sin θr and cos θr atmultipliers adder 823. Then, a pulsation component is adjusted at again adjuster 83. This makes it possible to extract only a component that pulsates with a period of the mechanical angle phase θr.FIG. 4C shows 500 μs of Ts and 500 ms of Ta as examples of the set values of sampling period Ts and filter time constant Ta. -
FIG. 5 is a waveform chart indicating pulsation in a current detected at the current detectingpart 5 when an anomaly occurs in thecompressor 11 of theair conditioner 1 and a swinging load is produced. Such anomalies that a swinging load is produced in thecompressor 11 include damage to thebearing compressor 11, liquid compression in thecompression chamber 109, poor lubrication at a contact area in the compression mechanical section, and the like. InFIG. 5 , thecurve 50 a represents a current value waveform in a normal state detected at the current detectingpart 5 and thecurve 50 b represents a current value waveform at the time of a compressor anomaly. - The current detecting
part 5 illustrated inFIG. 3 detects a current of thecompressor motor 104 with a certain sampling period. - When such an anomaly as mentioned above is present in the
compressor 11 of theair conditioner 1, torque fluctuation in thecompressor motor 104 becomes more violent that at normal times and this also takes place in an applied current of thecompressor motor 104. For this reason, as indicated by thecurve 50 b inFIG. 5 , a pulsation value (or amplitude) Ia relative to an average current value Im is increased as compared with a pulsation value Iao at normal times. Since the applied current is also increased with increase in rotational speed of thecompressor motor 104, the average current value Im is also increased. Therefore, any anomaly in thecompressor 11 can be detected with accuracy with a current pulsation value Ia rather than an average current value. - A description will be given to an operation of the
air conditioner 1 performed when a compressor anomaly is detected from a current pulsation value. -
FIG. 6 indicates threshold values Ia1, Ia2 used for detecting a compressor anomaly from a current pulsation value. - It is desirable that the threshold values Ia1, Ia2 are set beforehand the operation, based on the testing of a normal compressor and a compressor inside which an anomaly is observed or the like. When as a result of determination at the
anomaly determining part 9, a current pulsation value Ia exceeds the threshold value Ia1 for a certain period of time (T1) as indicated by the broken line in the graph, an air conditioner user is notified of an anomaly from the anomalyinformation output portion 91. Or, maintenance personnel for the air conditioner are notified of the anomaly in the air conditioner by remote monitoring or a smartphone through the Internet or the like. Thus, the air conditioner can be maintained at an early stage. - When the current pulsation value exceeds the threshold Ia1 for a certain period of time (T1), the anomaly is at an initial stage; therefore, an operation can be continued during a predetermined period of time only by notifying a compressor anomaly to the user. However, in case of an air conditioner high in refrigerating capacity provided with a plurality of compressors, it is desirable to stop an operation of a compressor in which an anomaly is detected by the air conditioner control unit and causes any other compressor to be operated to ensure a refrigerating capacity. Ia1 is effective in detecting any event, such as damage to a bearing, in which an anomaly gradually progresses in proportion to an operating time of the compressor.
- When the current pulsation Ia is abruptly increased and exceeds the threshold value Ia2 before exceeding Ia1 for a certain period of time (T2) as indicated by the solid line in the graph in
FIG. 6 , that is equivalent a state in which an anomaly, such as damage to thebearing compressor 11. Since theanomaly determining part 9 determines that an anomaly has occurred in thecompressor 11, it is desirable to stop thecompressor 11 based on an alarm from the anomalyinformation output portion 91. -
FIG. 4D illustrates a configuration of the above-mentionedanomaly determining part 9 determining any anomaly in thecompressor 11. Theanomaly determining part 9 includes: astorage portion 91 storing threshold values Ia1, Ia2 beforehand the operation; afirst comparison portion 92 comparing information on a current pulsation value Ia outputted from thepulsation detecting part 8 with Ia1 stored in the storage portion; asecond comparison portion 93 comparing information on a current pulsation value Ia outputted from thepulsation detecting part 8 with Ia2 stored in thestorage portion 91; and the anomalyinformation output portion 94 that, in response to information on results of comparisons at thefirst comparison portion 92 and thesecond comparison portion 93, outputs anomaly information. -
FIG. 7 is a graph indicating change in torque observed while a turning scroll is rotated by one turn in a scroll compressor. During a refrigerant compression stroke at a scroll compressor, as mentioned above, a refrigerant sucked into a compression chamber is compressed as a volume of the compression chamber is gradually reduced with rotation of the turning scroll. During this stroke, torque is changed due to a refrigerant gas load while the turning scroll is rotated by one turn. - In a scroll compressor, as indicated in
FIG. 7 , a torque is changed by one cycle while a turning scroll is rotated by one turn, that is, a compressor motor is rotated by one turn. Therefore, even in a normal compressor, pulsation occurs in the number of rotations first-order component of the compressor motor. - Even in a normal compressor, this occurs with refrigerant compression. Therefore, an anomaly in a compressor can be detected with higher accuracy by taking into account current pulsation associated with the above-mentioned refrigerant compression and the like when setting threshold values Ia1 and Ia2 for a current pulsation value Ia, described with reference to
FIG. 6 . - Rotary compressors are also frequently used as a compressor of an
air conditioner 1. Like a scroll type, rotary compressors are also provided with a displacement type compression mechanism, in which the volume of a compression chamber is varied by a rotating rolling piston and as a result, a refrigerant is compressed. There are various types of rotary compressors, including one-cylinder type provided with a single compression chamber and two-cylinder type provided with two compression chambers. In case where two compression chambers are provided, compression strokes are shifted by 180 degrees in one rotation of a compressor motor. -
FIG. 8 schematically indicates change in torque that takes place while a compressor motor is rotated by one turn in a rotary compressor. Thecurve 51 a represents torque change in one-cylinder type and thecurve 51 b represents torque change in two-cylinder type. Since in two-cylinder type, compression strokes are shifted by 180 degrees, torque change equivalent to two cycles takes place in one rotation of a compressor motor as indicated by thecurve 51 b. Therefore, even in a normal compressor, current pulsation is observed in a second-order component of a number of rotations of the compressor motor. Therefore, components of a current pulsation value present in a normal compressor differ depending on the structure of the compressor. For this reason, any anomaly in a compressor of an air conditioner can be detected with higher accuracy by taking the foregoing into account when setting threshold values Ia1, Ia2 for a current pulsation value. - A description will be given to a processing flow of anomaly determination at the
anomaly determining part 9 with reference toFIG. 9 . - After start of an operation of the
compressor 11, a current pulsation value Ia outputted from thepulsation detecting part 8 that has received outputs from the current detectingpart 5 and thephase detecting part 6 is inputted (S901). Subsequently, it is confirmed whether this current pulsation value Ia has been inputted (S902). When a current pulsation value Ia has not been inputted (NO at S902), the processing is terminated. When a current pulsation value Ia has been inputted (YES at S902), the inputted current pulsation value Ia is compared with a threshold value Ia1 stored in thestorage portion 91 beforehand the operation (S902). - When the result of comparison at S902 reveals that the inputted current pulsation value Ia is smaller than the threshold value Ia1 (NO at S903), the processing returns to S902 and it is confirmed whether a current pulsation value Ia has been inputted from the
pulsation detecting part 8. When the result of comparison at S902 reveals that the inputted current pulsation value Ia is larger than the threshold value Ia1 (YES at S903), it is confirmed whether a state in which the inputted current pulsation value Ia is larger than the threshold value Ia1 and smaller than a threshold value Ia2 has continued (lasted) for a preset certain period of time (T1) (S904). - When it is determined at S904 that a state in which the current pulsation value Ia is larger than the threshold value Ia1 and smaller than the threshold value Ia2 has continued (lasted) for the preset certain period of time (T1) (YES at S904), anomaly information is outputted to the anomaly output part 94 (S905). The processing then returns to S902 and it is confirmed whether a current pulsation value Ia has been inputted from the
pulsation detecting part 8. - When it is determined at S904 that a state in which the current pulsation value Ia is larger than the threshold value Ia1 and smaller than the threshold value Ia2 has not yet continued for the preset certain period of time (T1) (NO at S904), the current pulsation value Ia is compared with the threshold value Ia2 stored in the
storage portion 91 beforehand the operation (S906). When the result of comparison at S906 reveals that the current pulsation value Ia is smaller than the threshold value Ia2, the processing returns to S902 and it is confirmed whether a current pulsation value Ia has been inputted from thepulsation detecting part 8. - When the result of comparison at S906 reveals that the current pulsation value Ia is larger than the threshold value Ia2 (YES at S906), it is confirmed whether this state in which the inputted current pulsation value Ia is larger than the threshold value Ia2 has continued (lasted) for a preset certain period of time (T2) (S907). When the state in which the current pulsation value Ia is larger than the threshold value Ia2 has not continued for the preset certain period of time (T2) (NO at S907), the processing returns to S902 and it is confirmed whether a current pulsation value Ia has been inputted from the
pulsation detecting part 8. - When the state in which the current pulsation value Ia is larger than the threshold value Ia2 has continued for the preset certain period of time (T2) or longer (YES at S907), emergency stop information is outputted from the anomaly
information output portion 94 for stopping the compressor 11 (S908). - A description will be given to a flow of processing at the
control unit 4 in this embodiment with reference toFIG. 10 . - After start of an operation of the
compressor 11, a motor current is detected at thecurrent calculation portion 51 of the current detecting part 5 (S1001) and αβ conversion is performed at theαβ conversion portion 52 using a result of the detection (S1002). On a result of the conversion, dq conversion is performed at the dq conversion portion 53 (S1003) and a result of the dq conversion is filtered at thefiltering portion 54 to calculate a q-axis current feedback value IqFb (S1004). The result of dq conversion by thedq conversion portion 53 at S1003 is also inputted to thephase detecting part 6. θdc is extracted at the d-axisphase extraction portion 61 and a mechanical angle phase θr is calculated at the mechanical angle phase calculation portion 62 (S1005). - Subsequently, information on the q-axis current feedback value IqFb obtained at the current detecting
part 5 and the mechanical angle phase θr obtained at thephase detecting part 6 is inputted to thepulsation detecting part 8 and is processed at thecalculation portion 81, the filteringportion 82, and theadder 823 to extract a pulsation component Ia (S1006). - Information on the pulsation component Ia extracted at the
pulsation detecting part 8 is inputted to theanomaly determining part 9 and any anomaly is predicted and detected in accordance with the processing flow described with reference toFIG. 9 . - That is, as shown in
FIG. 10 , it is confirmed whether a state in which the pulsation component Ia is larger than a preset threshold value Ia1 and smaller than a preset threshold value Ia2 has continued (lasted) for a preset certain period of time (T1) (S1007). When a result of the confirmation reveals that the state has continued (lasted) for the certain period of time (T1) (YES at S1007), information indicating that the state in which the pulsation component Ia is larger than the preset threshold value Ia1 and smaller than the preset threshold value Ia2 has continued (lasted) for the preset certain period of time (T1) is outputted from the anomaly information output portion 94 (S1008). The processing then returns to S1001 and is continued. - When a result of the confirmation at S1007 reveals that a state in which the pulsation component Ia is larger than the preset threshold value Ia1 and smaller than the preset Ia2 has not continued (lasted) for the preset certain period of time (T1) (NO at S1007), it is confirmed whether a state in which the pulsation component Ia is larger than the preset threshold value Ia2 has continued (lasted) for a preset certain period of time (T2). When a negative determination is made, the processing returns to S1001 and is continued. When an affirmative determination is made at S1009, emergency stop information is outputted from the anomaly information output portion 94 (S1010) and the operation of the
compressor 11 is stopped by thecontrol unit 4. The step S903 in the flowchart described with reference toFIG. 9 is omitted from the flowchart described with reference toFIG. 10 . The step S903 is substantially identical with a loop in which the processing proceeds from S1007 and is returned to S1001 by way of S1009; therefore, a description of the step is omitted. - According to the present invention, as described up to this point, any failure in a compressor provided in an air conditioner can be predicted and can be detected at an early stage. As a result, the air conditioner can be used with stability without stopping an operation for reason of any failure in the compressor.
-
-
- 1: air conditioner,
- 4: control unit,
- 5: current detecting part,
- 6: phase detecting part,
- 7: motor rotational speed detecting part,
- 8: pulsation detecting part,
- 9: anomaly determining part,
- 10: outdoor unit,
- 11: refrigerant compressor,
- 30: indoor unit,
- 104: motor,
- 106: fixed scroll,
- 108: turning scroll,
- 112, 113: bearing.
Claims (10)
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PCT/JP2015/075815 WO2017042949A1 (en) | 2015-09-11 | 2015-09-11 | Air conditioner provided with failure prognosis/detection means for compressor, and failure prognosis/detection method thereof |
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US20180347879A1 true US20180347879A1 (en) | 2018-12-06 |
US11280530B2 US11280530B2 (en) | 2022-03-22 |
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US (1) | US11280530B2 (en) |
EP (1) | EP3348835B1 (en) |
JP (1) | JP6434634B2 (en) |
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US11396876B2 (en) | 2018-06-05 | 2022-07-26 | Ebara Corporation | Control device, control system, control method, recording medium and machine learning device |
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WO2017042949A1 (en) | 2017-03-16 |
EP3348835A4 (en) | 2019-03-13 |
JPWO2017042949A1 (en) | 2018-03-29 |
JP6434634B2 (en) | 2018-12-05 |
CN108138762A (en) | 2018-06-08 |
CN108138762B (en) | 2019-08-02 |
US11280530B2 (en) | 2022-03-22 |
EP3348835B1 (en) | 2020-05-20 |
EP3348835A1 (en) | 2018-07-18 |
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